AD07.16-P-5000A | Common rail diesel injection (CDI) diagnosis, troubleshooting | 1.9.97 |
ENGINE 611.960 in MODEL 202.133 /134 /193 /194
Danger! | Risk of explosion due to ignition, risk of poisoning due to inhaling and swallowing fuel and risk of injury due to fuel coming into contact with skin and eyes. | Fire, sparks, naked flame and smoking forbidden. Only pour fuel into suitable, appropriately marked containers. Wear protective clothing when handling fuel. | |
Common rail diesel injection (CDI) diagnosis, previous knowledge | |||
| Common rail diesel injection (CDI), location of components | ||
Troubleshooting | |||
Complaint | Possible cause | Notes | |
EPC lamp and preglow indicator lamp: | |||
EPC lamp in instrument cluster comes on | Diagnosis, previous knowledge Read out fault code using diagnosis tool (e.g. HHT) and proceed related to fault code | ||
Preglow indicator lamp in instrument cluster does not come on when the preglow system is switched on. It is possible to start the engine. | Bulb | Instrument cluster A1 Fault memory Fault code | |
Preglow indicator lamp in instrument cluster does not come on Engine is difficult to start at low outside temperatures. | Preglow output voltage supply defective. Preglow output defective. | Fault memory Fault code | |
Preglow indicator lamp in instrument cluster comes on for approx. 1 minute while driving | Open-circuit in glow plugs | Fault memory Fault code | |
Preglow indicator lamp comes on while driving or intermittently | Short-circuit in preglow output. Communication between engine control module and preglow output faulty | Fault memory Fault code | |
Starting: | |||
Starter does not turn | No input or output at terminal 50 Starter enable from ETC control module No start enable from drive authorization Starter relay Starter |
Fault memory Fault code Fault memory Fault code Check | Refer to HHT, actual values, starting engine Refer to HHT, actual values, drive authorization |
Engine does not start. Starter turns. Rail pressure approx. 60 bar On/off ratio of pressure control valve, 0% | Crankshaft position sensor | Check actual value of synchronization while starting engine | Refer to HHT, actual values, starting engine |
Engine does not start Starter turns Rail pressure < 120 bar Refer to HHT, actual values, starting engine | Fuel tank level Hydraulics Pressure control valve Injectors Crankshaft position sensor | Refuel Low-pressure circuit, testing hydraulics Fault memory Fault code Fault memory Fault code Fault memory Fault codes to Fault memory Fault codes | |
Engine does not start. Starter turns Rail pressure > 120 bar (refer to HHT, actual values, starting engine) | Injector plugs transposed. Synchronization Mechanical defect in engine Injectors | Check allocation, firing order 1,3,4,2 Check actual value of synchronization while starting engine Carry out compression test using diagnosis tool Fault memory Fault codes to Fault memory Fault codes , |
Refer to HHT, actual values, starting engine Refer to HHT, actuations, compression test |
Engine does not start. Starter turns. Rail pressure increases slightly initially but then drops to zero again. | Restriction point in fuel return flow Hydraulics | Eliminate any kinks Low-pressure circuit, testing hydraulics | |
Cold start: | |||
Engine shakes during the cold-running phase | Injectors | Carry out smooth-running correction using diagnosis tool | HHT: refer to actual values, checking idle, smooth-running correction |
Idle: | |||
Engine shakes at idle Rail pressure fluctuations < 8 bar (refer to actual values, checking idle) | Mechanical defect in engine Injectors | Carry out compression test using diagnosis tool Carry out smooth-running correction using diagnosis tool | HHT: Refer to actuations, compression test HHT: Refer to actual values, checking idle, smooth-running correction |
Engine shakes at idle Rail pressure fluctuations > 8 bar (refer to HHT, actual values, checking idle) | High-pressure pump delivers uneven quantity of fuel Injectors |
Carry out smooth-running correction using diagnosis tool | Replace high-pressure pump HHT: Refer to actual values, checking idle, smooth-running correction |
Driving mode: | |||
Engine stalls in driving mode | Fuel tank level Crankshaft position sensor Leakage on low-pressure side Pressure control valve Injectors Airbag signal | Refuel Fault memory Fault code Low-pressure circuit, testing hydraulics Fault memory Fault code Fault memory Fault code Fault memory Fault codes to Fault codes , Fault memory Fault code | |
Driving mode, load, load change: | |||
Engine stalls under load | Hydraulics Injectors Pressure control valve on stop | Low-pressure circuit, testing hydraulics High-pressure circuit, testing hydraulics Injector leak quantity, testing hydraulics Fault memory Fault codes , Fault code | |
Engine stalls when load changes | Leakage on low-pressure side Rail pressure monitoring | Check all fuel lines and connections for restriction points or damage Low-pressure circuit, testing hydraulics Fault memory Fault code | |
Insufficient power: | |||
Engine produces insufficient power Injection quantity within tolerance band Too much smoke (refer to HHT, actual values, driving mode, specified values) | Wrong fuel Air cleaner Charge air system Exhaust gas recirculation EGR valve Hot film MAF sensor Inlet port shut-off | Change fuel Visual inspection Fault memory Fault code Fault memory Fault code Fault memory Fault code | |
Engine produces insufficient power Injection quantity within tolerance band Smoke within tolerance band (refer to HHT, actual values, driving mode, specified values) | Exhaust emission system A/C compressor shut-off | Check exhaust emission system Fault memory Fault code | |
Engine produces insufficient power Injection quantity within tolerance band Smoke within tolerance band No boost pressure (refer to HHT, actual values, driving mode) | Charge air system leaking Hoses have slipped off, leaking Pressure control flap jams closed Vacuum supply of boost pressure control vacuum transducer Pressure sensor Boost pressure control | Visual inspection Visual inspection Vacuum circuit, testing pneumatics Fault memory Fault code Fault memory Fault code | |
Engine noise: | |||
Engine knocks Harsh engine noise | Injector plugs transposed Mechanical defect in engine Injectors | Check allocation, firing order 1,3,4,2 Carry out compression test using diagnosis tool Carry out smooth-running correction using diagnosis tool |
HHT: Refer to actuations, compression test HHT: Refer to actual values, checking idle, smooth-running correction |
Engine hunts | Mechanical defect in engine Injectors Restriction point in fuel return flow | Carry out compression test using diagnosis tool Carry out smooth-running correction using diagnosis tool Low-pressure circuit, testing hydraulics | HHT: Refer to actuations, compression test HHT: Refer to actual values, checking idle, smooth-running correction |
Referenced documents
- ad0000p200003a Connecting Hand-Held Tester (HHT), reading out fault memory
- ad0716p2000a Common-rail diesel injection (CDI) diagnosis, previous knowledge
- ad0716p4000a Common rail diesel injection (CDI) diagnosis, fault memory
- ad0716p4000aa Common rail diesel injection (CDI) diagnosis fault memory
- ad0716p4000ab Common rail diesel injection (CDI) diagnosis fault memory
- ad0716p7000a Common-Rail Diesel Injection (CDI), low-pressure circuit, testing hydraulics
- ad0716p7001a Common Rail Diesel Injection (CDI) - Testing the Extent of Leakage in Injectors of the Hydraulic System
- ad0716p7003i Common rail diesel injection (CDI) high-pressure circuit hydraulic testing
- ad0716p8000i Common rail diesel injection (CDI) diagnosis, vacuum circuit, testing pneumatic system
- as4700z000101a Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.
- gf0716p000101i Common-Rail Diesel Injection (CDI), location of components